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Bu çalışma, 07-08 Haziran 2010 tarihleri arasında Bursa[Türkiye]’da düzenlenen 5. Automotive Technology Conference (OTEKON)’da bildiri olarak sunulmuştur. A greater need to enhance comfort characteristics during vehicle design process has recently forced the manufacturers to develop simulation-based approaches. In this study, a simulation-based model of a full-car suspension system is proposed to predict the ride comfort. A simulation model was created for calculating ride comfort effectively. This simulation uses seat-back, seat-surface, and feet acceleration values collected from four different road vehicles which were run on six different roads. Parameters which effect ride comfort were also investigated. Using these parameters, a simulation-based model of a full-car suspension system including engine and seat is created for predicting the ride comfort. The correlation between the results of physical tests and the simulation is very promising. It was found that the effect of an engine has a substantial influence on the ride comfort. To find the optimum values of each parameter, an optimization process was executed properly and added in the model. Using this model, the best ride comfort values were computed without the need of physical prototypes. The developed algorithm can be very helpful as an assistant tool for engineers during vehicle design and manufacturing process. TOFAŞ-PLATFORM R&D A.Ş

This paper presents a framework for re-designing a failed automotive component subjected to cyclic loading. In the automotive industry, some parts fail before completing their design life. These failed components have to be re-designed using modern optimisation tools. In this paper, a failed clutch fork was completely re-designed using topology and the shape optimisation approach. Stress-life fatigue analysis was conducted to correlate the crack location between the failed component and the simulation model. A new design proposal was determined with the topology optimisation approach, and then design optimisation by response surface methodology was effectively used to improve the new clutch fork design. The mass reduction obtained was 24%. A maximum stress reduction of 9% was achieved, and the rigidity was improved up to 37% in comparison to the original clutch fork.

The engine mount systems have a significant effect with respect to reducing the vehicle development time and cost regarding NVH characteristics and shortcomings not solved yet. There is still a need to enhance the performance of engine mount systems for vehicle ride comfort. This research presents a simulation-based approach to design optimised engine mount components to isolate the road- and engine-induced vibrations without the need for physical prototypes. Experimental tests are performed to define hyperelastic and viscoelastic models for non-linear finite element simulations of rubber components. After the correlation between the results of simulations and the product tests, a virtual engine mount model is presented to design optimum engine mount systems with the desired static and dynamic characteristics. The stiffness curves of different shapes of designs are investigated, and the best curve is chosen as an optimum design solution using the design of experiments approach.

Although genetic algorithm and multi-objective optimization techniques are widely used to solve problems in the design and manufacturing area, further improvements are required to develop more efficient techniques regarding multi-objective optimization problems. The main goal of the present research is to further develop and strengthen the genetic algorithm based multi-objective optimization approach to generate real-world design solutions in the automotive industry. In this research, a new hybrid approach based on Taguchi's method and a genetic algorithm is presented to achieve better Pareto-optimal set solutions for multi-objective design optimization problems. In addition, fatigue damage and life are also considered to evaluate the results of the design optimization process. The validity and efficiency of the proposed approach are evaluated and illustrated with test problems taken from the literature. It is then applied to a vehicle component taken from the automotive industry.

The goal of this research is to describe how simulation and topology design can be used as a die design frame tool to introduce optimal die design structures with the desired maximum rigidity and minimum deformations using response surface methodology and differential evolution algorithms. In the simulation process, not only die deflection, but also press table deflection is taken into account in order to achieve more realistic results. The validation of the present approach is evaluated by a comparison of test and simulation results. In the experimental test, acceleration and strain data were measured from critical points of the die structure in order to obtain the maximum displacement and stress values. The optimal shape parameters for the die structure were obtained using response surface methodology and differential evolution as a fundamental optimisation technique. Significant results were obtained: The mass was reduced approximately about 24 %, and the current maximum stress decreased approximately about 72 %. By using this methodology in the design stage of die and sheet metal stamping, major improvements can be made to the vehicle development process, such as reducing the weight and the cost of die, reducing the labour costs during the tryout process and reducing the environmental damage and CO2 emissions by reducing the amount of cast iron.